Battery system having a battery module

ABSTRACT

A battery system includes a battery module that utilizes the first and second retention housings to hold a battery cell retention frame therein that can be either air cooled or fluid cooled. In particular, the first and second retention housings have an inlet port and an outlet port, respectively, for routing fluid through the battery cell retention frame for cooling cylindrical battery cells thereon. Alternately, the battery cell retention frame can be air cooled for cooling the cylindrical battery cells. Also, the first and second retention housings provide improved structural integrity to the battery module.

BACKGROUND

Battery modules with cylindrical battery cells are being utilized innumerous applications. Since it is desirable that the battery moduleshave a high energy/power output, the battery modules need effective andefficient cooling systems for optimal performance. In order to achievethe desired cooling efficiency, other cooling systems have utilizedcomplex tooling/assembly and components, which substantially increasethe overall cost. Further, known battery modules can either be aircooled or fluid cooled but do not have the flexibility to be both aircooled and fluid cooled.

The inventors herein have recognized a need for a battery system thatutilizes a battery module having first and second retention housingsthat hold a battery cell retention frame therein that can be either aircooled or fluid cooled. In particular, the first and second retentionhousings have an inlet port and an outlet port, respectively, forrouting fluid through the battery cell retention frame for coolingcylindrical battery cells thereon. Alternately, the battery cellretention frame can be air cooled to cool the cylindrical battery cells.Also, the first and second retention housings provide improvedstructural integrity to the battery module.

SUMMARY

A battery system in accordance with an exemplary embodiment is provided.The battery system includes a battery module having a battery cellretention frame, a first retention housing, and a second retentionhousing. The battery cell retention frame has a central cooling platemember, and first and second exterior plates. The central cooling platemember has first and second manifold portions and first and secondintermediate walls disposed between and coupled to the first and secondmanifold portions. The first and second intermediate walls define aninternal cooling channel therebetween that fluidly communicates with thefirst and second manifold portions. The first and second exterior platesare coupled to the first and second manifold portions, respectively, andextend perpendicular to the central cooling plate member. The firstretention housing is disposed within a region defined by the firstintermediate wall and the first and second exterior plates. The firstretention housing has an end wall and first, second, third, and fourthside walls defining a first interior region. The first, second, third,and fourth side walls of the first retention housing are coupled to theend wall thereof and define a first open end. The first retentionhousing holds a first plurality of cylindrical battery cells thereinthat thermally communicate with the first intermediate wall. The firstside wall of the first retention housing has an inlet port that fluidlycommunicates with the first manifold portion. The second retentionhousing is disposed within a region defined by the second intermediatewall and the first and second exterior plates. The second retentionhousing has an end wall and first, second, third, and fourth side wallsdefining a second interior region. The first, second, third, and fourthside walls of the second retention housing are coupled to the end wallthereof and define a second open end. The second retention housing holdsa second plurality of cylindrical battery cells therein that thermallycommunicate with the second intermediate wall. The first side wall ofthe second retention housing has an outlet port that fluidlycommunicates with the second manifold portion. The battery systemfurther includes a fluid supply system that is fluidly coupled to inletport and the outlet port, the fluid supply system supplying a fluid tothe inlet port such the fluid flows through the first manifold portionof the battery cell retention frame and the internal cooling channel ofthe battery cell retention frame, and the second manifold portion of thebattery cell retention frame and out of the outlet port to extract heatenergy from the first and second plurality of battery cells

A battery module in accordance with an exemplary embodiment is provided.The battery module includes a battery cell retention frame having acentral cooling plate member, and first and second exterior plates. Thecentral cooling plate member has first and second manifold portions andfirst and second intermediate walls disposed between and coupled to thefirst and second manifold portions. The first and second intermediatewalls define an internal cooling channel therebetween that fluidlycommunicates with the first and second manifold portions. The first andsecond exterior plates are coupled to the first and second manifoldportions, respectively, and extend perpendicular to the central coolingplate member. The battery module further includes a first retentionhousing that is disposed within a region defined by the firstintermediate wall and the first and second exterior plates. The firstretention housing has an end wall and first, second, third, and fourthside walls defining a first interior region. The first, second, third,and fourth side walls of the first retention housing are coupled to theend wall thereof and define a first open end. The first retentionhousing holds a first plurality of cylindrical battery cells thereinthat thermally communicate with the first intermediate wall. The firstside wall of the first retention housing has an inlet port that fluidlycommunicates with the first manifold portion. The battery moduleincludes a second retention housing that is disposed within a regiondefined by the second intermediate wall and the first and secondexterior plates. The second retention housing having an end wall andfirst, second, third, and fourth side walls defining a second interiorregion. The first, second, third, and fourth side walls of the secondretention housing are coupled to the end wall thereof and define asecond open end. The second retention housing holds a second pluralityof cylindrical battery cells therein that thermally communicate with thesecond intermediate wall. The first side wall of the second retentionhousing has an outlet port that fluidly communicates with the secondmanifold portion.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a schematic of a battery system having a battery module and afluid supply system in accordance with an exemplary embodiment;

FIG. 2 is an isometric view of the battery module of FIG. 1 ;

FIG. 3 is another isometric view of the battery module of FIG. 1 ;

FIG. 4 is a top view of the battery module of FIG. 1 ;

FIG. 5 is a side view of the battery module of FIG. 1 ;

FIG. 6 is a cross-sectional view of the battery module of FIG. 1 takenalong lines 6-6 in FIG. 1 ;

FIG. 7 is another side view of the battery module of FIG. 1 ;

FIG. 8 is an exploded view of the battery module of FIG. 1 ;

FIG. 9 is another exploded view of the battery module of FIG. 1 ;

FIG. 10 is a cross-sectional view of the battery module of FIG. 3 takenalong lines 10-10 in FIG. 3 that illustrates the heat transfer fromcylindrical battery cells into a battery cell retention frame;

FIG. 11 is an isometric view of a battery cell retention frame utilizedin the battery module of FIG. 1 ;

FIG. 12 is another isometric view of the battery cell retention frame ofFIG. 11 ;

FIG. 13 is another isometric view of the battery cell retention frame ofFIG. 11 ;

FIG. 14 is another isometric view of the battery cell retention frame ofFIG. 11 ;

FIG. 15 is an enlarged isometric view of the battery cell retentionframe of FIG. 11 ;

FIG. 16 is a front view of the battery cell retention frame of FIG. 11 ;

FIG. 17 is a side view of the battery cell retention frame of FIG. 11 ;

FIG. 18 is a top view of the battery cell retention frame of FIG. 11 ;

FIG. 19 is a cross-sectional view of the battery cell retention frame ofFIG. 13 taken along lines 19-19 in FIG. 13 ;

FIG. 20 is a cross-sectional view of the battery cell retention frame ofFIG. 13 taken along lines 20-20 in FIG. 13 ;

FIG. 21 is an isometric view of the battery cell retention frame of FIG.11 illustrating where fluid enters and exits the battery cell retentionframe;

FIG. 22 is a top view of the battery cell retention frame of FIG. 11illustrating where fluid traverses across the battery cell retentionframe in an internal cooling channel;

FIG. 23 is an isometric view of a first retention housing utilized inthe battery module of FIG. 1 ;

FIG. 24 is an isometric view of the first retention housing of FIG. 23holding a first plurality of cylindrical battery cells, and first andsecond retaining plates therein;

FIG. 25 is a top view of the first retention housing of FIG. 23 ;

FIG. 26 is a bottom view of the first retention housing, the firstplurality of cylindrical battery cells, and the first and secondretaining plates of FIG. 24 ;

FIG. 27 is a side view of the first retention housing of FIG. 23 ;

FIG. 28 is another side view of the first retention housing of FIG. 23 ;

FIG. 29 is another side view of the first retention housing of FIG. 23 ;

FIG. 30 is a partial exploded view of the first retention housing ofFIG. 23 , the first plurality of cylindrical battery cells, and thefirst and second retaining plates;

FIG. 31 is another partial exploded view of the first retention housing,the first plurality of cylindrical battery cells, and the first andsecond retaining plates of FIG. 30 ;

FIG. 32 is an isometric view of the first retention housing of FIG. 23without first and second electrical bus bars therein;

FIG. 33 is another isometric view of the first retention housing of FIG.32 ;

FIG. 34 is an enlarged top view of the first retention housing of FIG.32 ;

FIG. 35 is an enlarged bottom view of the first retention housing ofFIG. 32 ;

FIG. 36 is a side view of the first retention housing of FIG. 32 ;

FIG. 37 is another side view of the first retention housing of FIG. 32 ;

FIG. 38 is partial cut-a-way view of the first retention housing of FIG.37 illustrating an inlet port;

FIG. 39 is schematic of a first plurality of cylindrical battery cellsutilized in the battery module of FIG. 1 ;

FIG. 40 is an enlarged view of a cylindrical battery cell of the firstplurality of cylindrical battery cells of FIG. 39 ;

FIG. 41 is an isometric view of a second retention housing utilized inthe battery module of FIG. 1 ;

FIG. 42 is an isometric view of the second retention housing of FIG. 41holding a second plurality of cylindrical battery cells, and third andfourth retaining plates therein;

FIG. 43 is a top view of the second retention housing of FIG. 41 ;

FIG. 44 is a bottom view of the second retention housing, the secondplurality of cylindrical battery cells, and the third and fourthretaining plates of FIG. 42 ;

FIG. 45 is a side view of the second retention housing of FIG. 41 ;

FIG. 46 is another side view of the second retention housing of FIG. 41;

FIG. 47 is another side view of the second retention housing of FIG. 41;

FIG. 48 is a partial exploded view of the second retention housing ofFIG. 41 , the second plurality of cylindrical battery cells, and thethird and fourth retaining plates;

FIG. 49 is another partial exploded view of the second retentionhousing, the second plurality of cylindrical battery cells, and thethird and fourth retaining plates of FIG. 48 ;

FIG. 50 is an isometric view of the second retention housing of FIG. 41without first and second electrical bus bars therein;

FIG. 51 is another isometric view of the second retention housing ofFIG. 50 ;

FIG. 52 is an enlarged top view of the second retention housing of FIG.50 ;

FIG. 53 is an enlarged bottom view of the second retention housing ofFIG. 50 ;

FIG. 54 is a side view of the second retention housing of FIG. 50 ;

FIG. 55 is another side view of the second retention housing of FIG. 50;

FIG. 56 is partial cut-a-way view of the second retention housing ofFIG. 55 illustrating an outlet port;

FIG. 57 is schematic of a second plurality of cylindrical battery cellsutilized in the battery module of FIG. 1 ;

FIG. 58 is an isometric view of a first outer plate utilized in thebattery module of FIG. 1 ;

FIG. 59 is another isometric view of the first outer plate of FIG. 58 ;

FIG. 60 is a bottom view of the first outer plate of FIG. 58 ;

FIG. 61 is a top view of the first outer plate of FIG. 58 ;

FIG. 62 is an isometric view of a second outer plate utilized in thebattery module of FIG. 1 ;

FIG. 63 is another isometric view of the second outer plate of FIG. 62 ;

FIG. 64 is a bottom view of the second outer plate of FIG. 62 ;

FIG. 65 is a top view of the second outer plate of FIG. 62 ;

FIG. 66 is an enlarged schematic of a portion of the battery module ofFIG. 1 ;

FIG. 67 is an isometric view of a cover plate utilized in the batterymodule of FIG. 1 ;

FIG. 68 is another isometric view of the cover plate of FIG. 67 ;

FIG. 69 is a schematic of the first and second retention housings andthe battery cell retention frame prior to coupling the componentstogether;

FIG. 70 is a schematic of the first and second retention housings andthe battery cell retention frame coupled together;

FIG. 71 is an enlarged schematic of a portion of the first retentionhousing and the battery cell retention frame of FIG. 70 ;

FIG. 72 is a schematic of the first and second retention housings priorto the first and second outer plates being coupled to the first andsecond retention housings, respectively;

FIG. 73 is a schematic of the first and second outer plates coupled tothe first and second retention housings, respectively;

FIG. 74 is a cross-sectional view of the battery module of FIG. 3 takenalong lines 10-10 in FIG. 3 that illustrates the heat transfer fromcylindrical battery cells into a battery cell retention frame when afluid supply system is not coupled to the battery module.

DETAILED DESCRIPTION

Referring to FIGS. 1-10 , a battery system 20 having a fluid supplysystem 30 and a battery module 32 in accordance with an exemplaryembodiment is provided.

The fluid supply system 30 is provided to supply a fluid to the batterymodule 32 for cooling cylindrical battery cells within the batterymodule 32. The fluid supply system 30 includes a fluid supply device 40and conduits 42, 44. The conduit 42 is coupled to and between the fluidsupply device 40 and an inlet port 640 of the battery module 20.Further, the conduit 44 is coupled to and between the fluid supplydevice 40 and an outlet port 1640 of the battery module 20. Duringoperation, the fluid supply device 40 pumps fluid through the conduit 42and into the inlet port 640. The fluid is routed through the batterymodule 32 to cool the cylindrical battery cells therein and then out ofthe outlet port 1640 and through the conduit 44 back to the fluid supplydevice 30.

Referring to FIGS. 8 and 9 , the battery module 32 is provided to outputan operational voltage. The battery module 32 includes a battery cellretention frame 50, a first retention housing 54, a first plurality ofcylindrical battery cells 56, first and second retaining plates 60, 62(shown in FIG. 24 ), a second retention housing 74, a second pluralityof cylindrical battery cells 76 (shown in FIG. 42 ), third and fourthretaining plates 80, 82 (shown in FIG. 42 ), a first outer plate 90,bolts 91, 92, 93, 94, a second outer plate 100, bolts 101, 102, 103,104, a circuit board 120, an electrical bus bar 122, a circuit board124, and a cover plate 126.

Referring to FIGS. 1-10 , an advantage of the battery module 32 is thatthe battery module 32 utilizes the first and second retention housings54, 74 to hold the battery cell retention frame 50 therein that can beeither air cooled or fluid cooled. In particular, the first and secondretention housings 54, 74 have an inlet port 640 and an outlet port1640, respectively, for routing fluid through the battery cell retentionframe 50 for cooling cylindrical battery cells thereon. Alternately, thebattery cell retention frame 50 can be air cooled for cooling thecylindrical battery cells. Also, the first and second retention housings54, 74 provide improved structural integrity to the battery module 32.

Battery Cell Retention Frame

Referring to FIGS. 11-22 , the battery cell retention frame 50 isprovided to hold and to cool the first plurality of cylindrical batterycells 56 and the second plurality of cylindrical battery cells 76thereon. The battery cell retention frame 50 includes a central coolingplate member 140, a first exterior plate 141, a second exterior plate142, a first thermally conductive layer 151, and a second thermallyconductive layer 152. An advantage of the battery cell retention frame50 is that frame 50 can hold and cool the first and second plurality ofcylindrical battery cells 56, 76 on opposite sides of the centralcooling plate member 50 while supporting and protecting the batterycells 56, 76 with the first and second exterior plates 141, 142. In anexemplary embodiment, the central cooling plate member 140, the firstexterior plate 141, and the second exterior plate 142 are constructed ofa metal such as aluminum for example. The first and second thermallyconductive layers 151 and 152 are constructed of a thermally conductivematerial that is not electrically conductive.

Central Cooling Plate Member

Referring to FIGS. 19 and 20 , the central cooling plate member 140includes a first manifold portion 161, a second manifold portion 162, afirst intermediate wall 171, a second intermediate wall 172, a first endplate 181, a second end plate 182, and an internal cooling channel 184.

First Manifold Portion

Referring to FIGS. 14 and 18-20 , the first manifold portion 161includes a first end 191 (shown in FIG. 18 ), a second end 192, acentral body portion 200, a first extension portion 201, and a secondextension portion 202.

Central Body Portion

The central body portion 200 extends along a longitudinal axis 212(shown in FIG. 18 ). The central body portion 200 includes an inletaperture 208 (shown in FIGS. 14 and 20) and a longitudinal aperture 210(shown in FIG. 19 ). The inlet aperture 208 extends through a bottomsurface of the central body portion 200 and fluidly communicates withthe longitudinal aperture 210. The longitudinal aperture 210 extendsalong the longitudinal axis 212 from the first end 191 to the second end192.

First and Second Extension Portions

The first and second extension portions 201, 202 are coupled to oppositesides of the central body portion 200. The first extension portion 201has a flow aperture 214 extending therethrough that fluidly communicateswith the longitudinal aperture 210 of the central body portion 200 andthe internal cooling channel 184. The flow aperture 214 has a verticalheight that is less than a diameter of the longitudinal aperture 210.The second extension portion 202 is coupled to and between the centralbody portion 200 and the first exterior plate 141.

Second Manifold Portion

The second manifold portion 162 includes a first end 221 (shown in FIG.18 ), a second end 222, a central body portion 230, a first extensionportion 231, and a second extension portion 232.

Central Body Portion

The central body portion 230 extends along a longitudinal axis 242(shown in FIG. 18 ). The central body portion 230 includes an outletaperture 238 and a longitudinal aperture 240. The outlet aperture 238extends through a top surface of the central body portion 230 andfluidly communicates with the longitudinal aperture 240. Thelongitudinal aperture 240 extends along the longitudinal axis 242 fromthe first end 221 to the second end 222.

First and Second Extension Portions

The first and second extension portions 231, 232 are coupled to oppositesides of the central body portion 230. The first extension portion 231has a flow aperture 244 extending therethrough that fluidly communicateswith the longitudinal aperture 240 of the central body portion 230 andthe internal cooling channel 184. The flow aperture 244 has a verticalheight that is less than a diameter of the longitudinal aperture 240.The second extension portion 232 is coupled to and between the centralbody portion 230 and the second exterior plate 142.

First and Second Intermediate Walls

Referring to FIGS. 18-20 , the first and second intermediate walls 171,172 are disposed between and coupled to the first and second manifoldportions 161, 162. The first and second intermediate walls 171, 172define the internal cooling channel 184 therebetween that fluidlycommunicates with the first and second manifold portions 161, 162. Thefirst intermediate wall 171 includes a first end 251 (shown in FIG. 18), a second end 252, and an outer surface 253. Further, the secondintermediate wall 172 includes a first end 261 (shown in FIG. 18 ), asecond end 262, and an outer surface 263.

First End Plate

Referring to FIGS. 11, 13 and 18 , the first end plate 181 is providedto enclose an end of the battery cell retention frame 50. In particular,the first end plate 181 is coupled to a first end 251 (shown in FIG. 18) of the first intermediate wall 171, a first end 261 of the secondintermediate wall 172, a first end 191 of the first manifold portion161, and a first end 221 of the second manifold portion 162.

Second End Plate

The second end plate 182 is provided to enclose another end of thebattery cell retention frame 50. In particular, the second end plate 182is coupled to a second end 252 (shown in FIG. 18 ) of the firstintermediate wall 171, a second end 262 of the second intermediate wall172, a second end 192 of the first manifold portion 161, and a secondend 222 of the second manifold portion 162.

Internal Cooling Channel

Referring to FIGS. 19 and 20 , the internal cooling channel 184 has avertical height that is greater than a vertical height of the flowaperture 214 of the first extension portion 201 of the first manifoldportion 161. Further, the internal cooling channel 184 has a verticalheight that is greater than a vertical height of the flow aperture 244in the first extension portion 231 of the second manifold portion 162.

First Thermally Conductive Layer

Referring to FIGS. 10, 19 and 20 , the first thermally conductive layer151 is provided to conduct heat energy from the first plurality ofcylindrical battery cells 56 to the central cooling plate member 140.The first thermally conductive layer 151 is disposed on the first outersurface 253 of the first intermediate wall 171.

Second Thermally Conductive Layer

The second thermally conductive layer 152 is provided to conduct heatenergy from the second plurality of cylindrical battery cells 76 to thecentral cooling plate member 140. The second thermally conductive layer152 is disposed on the outer surface 263 of the second intermediate wall172.

First and Second Exterior Plates

Referring to FIGS. 19 and 20 , the first and second exterior plates 141,142 are coupled to the first and second manifold portions 161, 162,respectively, of the central cooling plate member 140 and extendperpendicular to the central cooling plate member 140. The first andsecond intermediate walls 171, 172 have first and second outer surfaces253, 263, respectively, disposed opposite to one another and between thefirst and second exterior plates 141, 142.

First Exterior Plate

The first exterior plate 141 is provided to radiate heat energy from thecentral cooling plate member 140 to ambient atmosphere and to protectthe first and second plurality of cylindrical battery cells 56, 76. Thefirst exterior plate 141 includes a central exterior plate portion 280,a first rail portion 281, and a second rail portion 282.

The first and second rail portions 281, 282 extend longitudinally andare coupled to first and second ends, respectively, of the centralexterior plate portion 280. The central exterior plate portion 280 has acorrugated outer surface 290.

The first rail portion 281 includes a curved portion 296 (shown in FIG.19 ), and a head portion 298 having an end surface 299. The curvedportion 296 is coupled to and between the head portion 298 and thecentral exterior plate portion 280. The first rail portion 281 furtherincludes apertures 301, 302 (shown in FIG. 13 ) extending into the endsurface 299.

The second rail portion 282 includes a curved portion 306, and a headportion 308 having an end surface 309. The curved portion 306 is coupledto and between the head portion 308 and the central exterior plateportion 280. The second rail portion 282 further includes apertures 311,312 (shown in FIG. 13 ) extending into the end surface 309.

Second Exterior Plate

The second exterior plate 142 is provided to radiate heat energy fromthe central cooling plate member 140 to ambient atmosphere and toprotect the first and second plurality of cylindrical battery cells 56,76. The second exterior plate 142 includes a central exterior plateportion 340, a first rail portion 341, and a second rail portion 342.

The first and second rail portions 341, 342 extend longitudinally andare coupled to first and second ends, respectively, of the centralexterior plate portion 340. The central exterior plate portion 340 has acorrugated outer surface 350.

The first rail portion 341 includes a curved portion 356 (shown in FIG.19 ), and a head portion 358 having an end surface 359. The curvedportion 356 is coupled to and between the head portion 358 and thecentral exterior plate portion 340. The first rail portion 341 furtherincludes apertures 361, 362 (shown in FIG. 13 ) extending into the endsurface 359.

The second rail portion 342 includes a curved portion 366, and a headportion 368 having an end surface 369. The curved portion 366 is coupledto and between the head portion 368 and the central exterior plateportion 340. The second rail portion 342 further includes apertures 371,372 (shown in FIG. 13 ) extending into the end surface 369.

Regions

The first and second exterior plates 141, 142 and the first intermediatewall 171 define a region 401 for receiving the first plurality ofcylindrical battery cells 56 therein. Further, the first and secondexterior plates 141, 142 and the thermally conductive layer 152 define aregion 402 for receiving the second plurality of cylindrical batterycells 76 therein.

First Retention Housing

Referring to FIGS. 19 and 23-38 , the first retention housing 54 holdsthe first plurality of cylindrical battery cells 56 therein and on andagainst the first thermally conductive layer 151 (shown in FIG. 19 )such that the battery cells 56 thermally communicate through the layer151 with the first intermediate wall 171. The first retention housing 54is disposed within the region 401 (shown in FIG. 19 ) defined by thefirst intermediate wall 171 and the first and second exterior plates141, 142. Referring to FIGS. 23 and 25 , the first retention housing 54has an end wall 450, a first side wall 451, a second side wall 452, athird side wall 453, a fourth side wall 454, an electrical bus bar 456,and an electrical bus bar 458. The first and second side walls 451, 452extend substantially parallel to one another. Further, the third andfourth side walls 453, 454 extend substantially parallel to one anotherand perpendicular to the first and second side walls 451, 452. In anexemplary embodiment, the end wall 450 and the first, second, third, andfourth side walls 451, 452, 453, 454 are constructed of plastic.Further, the electrical bus bars 456 and 458 are constructed of copper.

End Wall

The end wall 450 is coupled to the first, second, third, and fourth sidewalls 451, 452, 453, 454 to define an interior region 460 (shown in FIG.24 ) and an open end 462.

Referring to FIG. 34 , the end wall 450 includes a wall portion 600 witha plurality of apertures 470 extending therethrough. Each aperture ofthe plurality of apertures 470 is associated with a cylindrical batterycell of the first plurality of cylindrical battery cells 56. Theplurality of apertures 470 includes a first row of apertures 471, asecond row of apertures 472, a third row of apertures 473, a fourth rowof apertures 474, a fifth row of apertures 475, a sixth row of apertures476, and a seventh row of apertures 477.

Referring to FIGS. 34 and 35 , the end wall 450 includes a plurality ofalignment tabs 490 extending from the wall portion 600 into the interiorregion 460 (shown in FIG. 24 ) of the first retention housing 54 forreceiving the first plurality of cylindrical battery cells 56 thereinthat align with the plurality of apertures 470. The plurality ofalignment tabs 490 include a first row of alignment tabs 491, a secondrow of alignment tabs 492, a third row of alignment tabs 493, a fourthrow of alignment tabs 494, a fifth row of alignment tabs 495, a sixthrow of alignment tabs 496, and a seventh row of alignment tabs 497. Thefirst, second, third, fourth, fifth, sixth, seventh plurality ofalignment tabs 491, 492, 493, 494, 495, 496, 497 are aligned with thefirst, second, third, fourth, fifth, sixth, seventh plurality ofapertures 471, 472, 473, 474, 475, 476, 477, respectively. Further, eachalignment tab of the plurality of alignment tabs 490 is associated witha respective cylindrical battery cell of the first plurality ofcylindrical battery cells 56 and a respective aperture of the pluralityof apertures 470. For example, the alignment tab 500 in the first row ofalignment tabs 491 is aligned with the aperture 480 in the first row ofapertures 471 and holds the cylindrical battery cell 800 (shown in FIG.39 ).

Referring to FIG. 34 , the end wall 450 further includes tab members601, 602, 603, 604, 605, 606 extending upwardly from the wall portion600 for alignment with the first outer plate 90 (shown in FIG. 8 ).Further, the end wall 450 includes grooves 610, 612 extending into thewall portion 600 for receiving the electrical bus bars 456, 458 (shownin FIG. 25 ) therein.

First Side Wall

Referring to FIGS. 25 and 29 , the first side wall 451 is coupled to theend wall 450 and the third and fourth side walls 453, 454 and extends ina first direction perpendicular to the end wall 450. The first side wall451 includes a wall portion 628, a retaining clip member 630, and tabmembers 632, 634, 636, and an inlet port 640.

Referring to FIGS. 29 and 47 , the retaining clip 630 is coupled to thewall portion 628 and extends in a first direction from the wall portion628. The tab member 632 extends outwardly from the wall portion 628. Theretaining clip member 630 is coupled to the tab member 1632 (shown inFIG. 47 ) for coupling the first retention housing 54 to the secondretention housing 74. The tab member 632 is coupled to the retainingclip member 1630 (shown in FIG. 47 ) for coupling the first retentionhousing 54 to the second retention housing 74.

Referring to FIGS. 29 and 59 , the tab member 634 is coupled to theretaining clip member 1904 (shown in FIG. 59 ) of the first outer plate90 for coupling the first outer plate 90 to the first retention housing54. Further, the tab member 636 is coupled to the retaining clip member1902 (shown in FIG. 59 ) of the first outer plate 90 for coupling thefirst outer plate 90 to the first retention housing 54.

Referring to FIG. 38 , the first side wall 451 has an inlet port 640coupled to the wall portion 628 that fluidly communicates with the inletaperture 208 (shown in FIG. 20 ) of the first manifold portion 161 ofthe central cooling plate member 140 of the battery cell retention frame50. The inlet port 640 is routed at a 90° angle within an interiorregion 460 (shown in FIG. 24 ) of the first retention housing 54.

Second Side Wall

Referring to FIGS. 25 and 28 , the second side wall 452 is coupled tothe end wall 450 and the third and fourth side walls 453, 454 andextends in a first direction perpendicular to the end wall 450. Thesecond side wall 452 includes a wall portion 648, a retaining clipmember 650, and tab member 652.

Referring to FIGS. 28 and 46 , the retaining clip 650 is coupled to thewall portion 648 and extends in a first direction from the wall portion648. The tab member 652 extends outwardly from the wall portion 648. Theretaining clip member 650 is coupled to the tab member 1652 (shown inFIG. 46 ) for coupling the first retention housing 54 to the secondretention housing 74. The tab member 652 is coupled to the retainingclip member 1650 (shown in FIG. 46 ) for coupling the first retentionhousing 54 to the second retention housing 74.

Third Side Wall

Referring to FIGS. 25 and 27 , the third side wall 453 is coupled to theend wall 450 and the first and second side walls 451, 452 and extends ina first direction perpendicular to the end wall 450. The third side wall453 includes a wall portion 660.

Fourth Side Wall

Referring to FIGS. 23 and 25 , the fourth side wall 454 is coupled tothe end wall 450 and the first and second side walls 451, 452 andextends in a first direction perpendicular to the end wall 450. Thefourth side wall 454 includes a wall portion 670.

First Plurality of Cylindrical Battery Cells

Referring to FIGS. 10, 30, 31 and 39 , the first plurality ofcylindrical battery cells 56 are held within the first retention housing54 and against the battery cell retention frame 50. The first pluralityof cylindrical battery cells 56 includes a first row of battery cells751, a second row of battery cells 752, a third row of battery cells753, a fourth row of battery cells 754, a fifth row of battery cells755, a sixth row of battery cells 756, and a seventh row of batterycells 757.

In an exemplary embodiment, each battery cell of the first row ofbattery cells 751 are electrically coupled in parallel to one another.Further, each battery cell of the second row of battery cells 752 areelectrically coupled in parallel to one another. Further, each batterycell of the third row of battery cells 753 are electrically coupled inparallel to one another. Further, each battery cell of the fourth row ofbattery cells 754 are electrically coupled in parallel to one another.Further, each battery cell of the fifth row of battery cells 755 areelectrically coupled in parallel to one another. Further, each batterycell of the sixth row of battery cells 756 are electrically coupled inparallel to one another. Further, each battery cell of the seventh rowof battery cells 757 are electrically coupled in parallel to oneanother. Further, the first, second, third, fourth, fifth, sixth,seventh rows of battery cells 756 are electrically coupled in series toone another. Still further, each negative terminal of the battery cellsin the first row of battery cells 751 are electrically coupled to theelectrical bus bar 456 (shown in FIG. 31 ). Still further, each negativeterminal of the battery cells in the seventh row of battery cells 757are electrically coupled to the electrical bus bar 458 (shown in FIG. 31).

Referring to FIGS. 39 and 40 , since each of the cylindrical batterycells in the first plurality of cylindrical battery cells 56 have anidentical structure, only the structure of the cylindrical battery cell800 will be described in greater detail for purposes of simplicity. Thecylindrical battery cell 800 includes an outer side surface 802, abottom surface 804, a positive electrode 806, and the negative electrode808. The positive electrode 806 is surrounded by the negative electrode808. Further, the bottom surface 804 contacts the first thermallyconductive layer 151 (shown in FIG. 19 ) of the battery cell retentionframe 50 such that heat energy from the cylindrical battery cell 800 istransferred to the first thermally conductive layer 151.

First and Second Retaining Plates

Referring to FIGS. 30, 31, 34 and 39 , the first and second retainingplates 60, 62 are coupled to the first, second, third, fourth side walls451, 452, 453, 454 of the first retention housing 54 to hold the firstplurality of clinical battery cells 56 within the interior region 460(shown in FIG. 24 ) of the first retention housing 54. In an exemplaryembodiment, the first and second retaining plates 60, 62 are constructedof plastic.

Referring to FIG. 30 , the first retaining plate 60 includes a pluralityof apertures 830 extending therethrough. The plurality of apertures 830includes a first row of apertures 831, a second row of apertures 832, athird row of apertures 833, a fourth row of apertures 834, a fifth rowof apertures 835, a sixth row of apertures 836, and a seventh row ofapertures 837. Each aperture of the first plurality of apertures 830 issized to allow a bottom surface of a respective cylindrical battery cellto contact the first thermally conductive layer 151 while holding thecylindrical battery cell within the interior region 460 (shown in FIG.24 ) of the first retention housing 54.

The second retaining plate 62 includes a plurality of apertures 860extending therethrough. The plurality of apertures 860 includes a firstrow of apertures 861, a second row of apertures 862, a third row ofapertures 863, a fourth row of apertures 864, a fifth row of apertures865, a sixth row of apertures 866, and a seventh row of apertures867—which align with the first row of apertures 831, the second row ofapertures 832, the third row of apertures 833, the fourth row ofapertures 834, the fifth row of apertures 835, the sixth row ofapertures 836, and the seventh row of apertures 837, respectively. Eachaperture of the plurality of apertures 860 is sized to allow a bottomsurface of a respective cylindrical battery cell to contact the firstthermally conductive layer 151 while holding the cylindrical batterycell within the interior region 460 of the first retention housing 54.

Referring to FIGS. 30 and 39 , the first row of apertures 831 of thefirst retaining plate 60, and the first row of apertures 861 of thesecond retaining plate 62 align with the first row of battery cells 751.Further, the second row of apertures 832 of the first retaining plate60, and the second row of apertures 862 of the second retaining plate 62align with the second row of battery cells 752. Further, the third rowof apertures 833 of the first retaining plate 60, and the third row ofapertures 863 of the second retaining plate 62 align with the third rowof battery cells 753. Further, the fourth row of apertures 834 of thefirst retaining plate 60, and the fourth row of apertures 864 of thesecond retaining plate 62 align with the fourth row of battery cells754. Further, the fifth row of apertures 835 of the first retainingplate 60, and the fifth row of apertures 865 of the second retainingplate 62 align with the fifth row of battery cells 755. Further, thesixth row of apertures 836 of the first retaining plate 60, and thesixth row of apertures 866 of the second retaining plate 62 align withthe sixth row of battery cells 756. Further, the seventh row ofapertures 837 of the first retaining plate 60, and the seventh row ofapertures 867 of the second retaining plate 62 align with the seventhrow of battery cells 757.

Second Retention Housing

Referring to FIGS. 19 and 41-56 , the second retention housing 74 holdsthe second plurality of cylindrical battery cells 76 therein and on andagainst the second thermally conductive layer 152 (shown in FIG. 19 )such that the battery cells 76 thermally communicate through the layer152 with the second intermediate wall 172. The second retention housing74 has an identical structure as the first retention housing 54. Thesecond retention housing 74 is disposed within the region 402 (shown inFIG. 19 ) defined by the second intermediate wall 172 and the first andsecond exterior plates 141, 142. Referring to FIGS. 41 and 43 , thesecond retention housing 74 has an end wall 1450, a first side wall1451, a second side wall 1452, a third side wall 1453, a fourth sidewall 1454, an electrical bus bar 1456, and an electrical bus bar 1458.The first and second side walls 1451, 1452 extend substantially parallelto one another. Further, the third and fourth side walls 1453, 1454extend substantially parallel to one another and perpendicular to thefirst and second side walls 1451, 1452. In an exemplary embodiment, theend wall 1450 and the first, second, third, and fourth side walls 1451,1452, 1453, 1454 are constructed of plastic. Further, the electrical busbars 1456 and 1458 are constructed of copper.

End Wall

The end wall 1450 is coupled to the first, second, third, and fourthside walls 1451, 1452, 1453, 1454 to define an interior region 1460(shown in FIG. 42 ) and an open end 1462.

Referring to FIG. 52 , the end wall 1450 includes a wall portion 1600with a plurality of apertures 1470 extending therethrough. Each apertureof the plurality of apertures 1470 is associated with a cylindricalbattery cell of the second plurality of cylindrical battery cells 756.The plurality of apertures 1470 includes a first row of apertures 1471,a second row of apertures 1472, a third row of apertures 1473, a fourthrow of apertures 1474, a fifth row of apertures 1475, a sixth row ofapertures 1476, and a seventh row of apertures 1477.

Referring to FIGS. 52 and 53 , the end wall 1450 includes a plurality ofalignment tabs 1490 extending from the wall portion 1600 into theinterior region 1460 (shown in FIG. 42 ) of the second retention housing74 for receiving the second plurality of cylindrical battery cells 76therein that align with the plurality of apertures 1470. The pluralityof alignment tabs 1490 include a first row of alignment tabs 1491, asecond row of alignment tabs 1492, a third row of alignment tabs 1493, afourth row of alignment tabs 1494, a fifth row of alignment tabs 1495, asixth row of alignment tabs 1496, and a seventh row of alignment tabs1497. The first, second, third, fourth, fifth, sixth, seventh pluralityof alignment tabs 1491, 1492, 1493, 1494, 1495, 1496, 1497 are alignedwith the first, second, third, fourth, fifth, sixth, seventh pluralityof apertures 1471, 1472, 1473, 1474, 1475, 1476, 1477, respectively.Further, each alignment tab of the plurality of alignment tabs 1490 isassociated with a respective cylindrical battery cell of the secondplurality of cylindrical battery cells 76 and a respective aperture ofthe plurality of apertures 1470. For example, the alignment tab 1500 inthe first row of alignment tabs 1491 is aligned with the aperture 1480in the first row of apertures 1471 and holds the cylindrical batterycell 1800 (shown in FIG. 57 ).

Referring to FIG. 52 , the end wall 1450 further includes tab members1601, 1602, 1603, 1604, 1605, 1606 extending upwardly from the wallportion 1600 for alignment with the second outer plate 100 (shown inFIG. 8 ). Further, the end wall 1450 includes grooves 1610, 1612extending into the wall portion 1600 for receiving the electrical busbars 1456, 1458 (shown in FIG. 41 ) therein.

First Side Wall

Referring to FIGS. 43 and 47 , the first side wall 1451 is coupled tothe end wall 1450 and the third and fourth side walls 1453, 1454 andextends in a first direction perpendicular to the end wall 1450. Thefirst side wall 1451 includes a wall portion 1628, a retaining clipmember 1630, and tab members 1632, 1634, 1636, and an outlet port 1640.

Referring to FIGS. 29 and 47 , the retaining clip 1630 is coupled to thewall portion 1628 and extends in a first direction from the wall portion1628. The tab member 1632 extends outwardly from the wall portion 1628.The retaining clip member 1630 is coupled to the tab member 632 (shownin FIG. 29 ) for coupling the second retention housing 74 to the firstretention housing 54. The tab member 1632 is coupled to the retainingclip member 630 (shown in FIG. 29 ) for coupling the second retentionhousing 74 to the first retention housing 54.

Referring to FIGS. 47 and 63 , the tab member 1634 is coupled to theretaining clip member 2004 (shown in FIG. 63 ) of the second outer plate100 for coupling the second outer plate 100 to the second retentionhousing 74. Further, the tab member 1636 is coupled to the retainingclip member 2002 (shown in FIG. 63 ) of the second outer plate 100 forcoupling the second outer plate 100 to the second retention housing 74.

Referring to FIG. 56 , the first side wall 1451 has an outlet port 1640coupled to the wall portion 1628 that fluidly communicates with theoutlet aperture 238 (shown in FIG. 20 ) of the second manifold portion162 of the central cooling plate member 140 of the battery cellretention frame 50. The outlet port 1640 is routed at a 90° angle withinan interior region 1460 (shown in FIG. 42 ) of the second retentionhousing 74.

Second Side Wall

Referring to FIGS. 43 and 46 , the second side wall 1452 is coupled tothe end wall 1450 and the third and fourth side walls 1453, 1454 andextends in a first direction perpendicular to the end wall 1450. Thesecond side wall 1452 includes a wall portion 1648, a retaining clipmember 1650, and tab member 1652.

Referring to FIGS. 28 and 46 , the retaining clip 1650 is coupled to thewall portion 1648 and extends in a first direction from the wall portion1648. The tab member 1652 extends outwardly from the wall portion 1648.The retaining clip member 1650 is coupled to the tab member 652 (shownin FIG. 28 ) for coupling the second retention housing 74 to the firstretention housing 54. The tab member 1652 is coupled to the retainingclip member 650 (shown in FIG. 28 ) for coupling the second retentionhousing 74 to the first retention housing 54.

Third Side Wall

Referring to FIGS. 43 and 45 , the third side wall 1453 is coupled tothe end wall 1450 and the first and second side walls 1451, 1452 andextends in a first direction perpendicular to the end wall 1450. Thethird side wall 1453 includes a wall portion 1660.

Fourth Side Wall

Referring to FIGS. 41 and 43 , the fourth side wall 1454 is coupled tothe end wall 1450 and the first and second side walls 1451, 1452 andextends in a first direction perpendicular to the end wall 1450. Thefourth side wall 1454 includes a wall portion 1670.

Second Plurality of Cylindrical Battery Cells

Referring to FIGS. 10, 48, 49 and 57 , the second plurality ofcylindrical battery cells 76 are held within the second retentionhousing 74 and against the battery cell retention frame 50. The secondplurality of cylindrical battery cells 76 includes a first row ofbattery cells 1751, a second row of battery cells 1752, a third row ofbattery cells 1753, a fourth row of battery cells 1754, a fifth row ofbattery cells 1755, a sixth row of battery cells 1756, and a seventh rowof battery cells 1757.

In an exemplary embodiment, each battery cell of the first row ofbattery cells 1751 are electrically coupled in parallel to one another.Further, each battery cell of the second row of battery cells 1752 areelectrically coupled in parallel to one another. Further, each batterycell of the third row of battery cells 1753 are electrically coupled inparallel to one another. Further, each battery cell of the fourth row ofbattery cells 1754 are electrically coupled in parallel to one another.Further, each battery cell of the fifth row of battery cells 1755 areelectrically coupled in parallel to one another. Further, each batterycell of the sixth row of battery cells 1756 are electrically coupled inparallel to one another. Further, each battery cell of the seventh rowof battery cells 1757 are electrically coupled in parallel to oneanother. Further, the first, second, third, fourth, fifth, sixth,seventh rows of battery cells 1756 are electrically coupled in series toone another. Still further, each negative terminal of the battery cellsin the first row of battery cells 1751 are electrically coupled to theelectrical bus bar 1456 (shown in FIG. 49 ). Still further, eachnegative terminal of the battery cells in the seventh row of batterycells 1757 are electrically coupled to the electrical bus bar 1458(shown in FIG. 49 ).

Referring to FIGS. 40 and 57 , each of the cylindrical battery cells inthe second plurality of cylindrical battery cells 76 have an identicalstructure as the cylindrical battery cell 800 previously describedherein and have a bottom surface that contacts the second thermallyconductive layer 152 (shown in FIG. 19 ) of the battery cell retentionframe 50.

Third and Fourth Retaining Plates

Referring to FIGS. 48, 49, 52 and 57 , the third and fourth retainingplates 80, 82 are coupled to the first, second, third, fourth side walls1451, 1452, 1453, 1454 of the second retention housing 74 to hold thesecond plurality of clinical battery cells 76 within the interior region1460 (shown in FIG. 42 ) of the second retention housing 74. In anexemplary embodiment, the third and fourth retaining plates 80, 82 areconstructed of plastic.

Referring to FIG. 48 , the third retaining plate 80 includes a pluralityof apertures 1830 extending therethrough. The plurality of apertures1830 includes a first row of apertures 1831, a second row of apertures1832, a third row of apertures 1833, a fourth row of apertures 1834, afifth row of apertures 1835, a sixth row of apertures 1836, and aseventh row of apertures 1837. Each aperture of the first plurality ofapertures 1830 is sized to allow a bottom surface of a respectivecylindrical battery cell to contact the second thermally conductivelayer 152 while holding the cylindrical battery cell within the interiorregion 1460 of the second retention housing 74.

The fourth retaining plate 82 includes a plurality of apertures 1860extending therethrough. The plurality of apertures 1860 includes a firstrow of apertures 1861, a second row of apertures 1862, a third row ofapertures 1863, a fourth row of apertures 1864, a fifth row of apertures1865, a sixth row of apertures 1866, and a seventh row of apertures1867—which align with the first row of apertures 1831, the second row ofapertures 1832, the third row of apertures 1833, the fourth row ofapertures 1834, the fifth row of apertures 1835, the sixth row ofapertures 1836, and the seventh row of apertures 1837, respectively.Each aperture of the plurality of apertures 1860 is sized to allow abottom surface of a respective cylindrical battery cell to contact thesecond thermally conductive layer 152 while holding the cylindricalbattery cell within the interior region 1460 (shown in FIG. 42 ) of thesecond retention housing 74.

Referring to FIGS. 48 and 57 , the first row of apertures 1831 of thethird retaining plate 80, and the first row of apertures 1861 of thefourth retaining plate 82 align with the first row of battery cells1751. Further, the second row of apertures 1832 of the third retainingplate 80, and the second row of apertures 1862 of the fourth retainingplate 82 align with the second row of battery cells 1752. Further, thethird row of apertures 1833 of the third retaining plate 80, and thethird row of apertures 1863 of the fourth retaining plate 82 align withthe third row of battery cells 1753. Further, the fourth row ofapertures 1834 of the third retaining plate 80, and the fourth row ofapertures 1864 of the fourth retaining plate 82 align with the fourthrow of battery cells 1754. Further, the fifth row of apertures 1835 ofthe third retaining plate 80, and the fifth row of apertures 1865 of thefourth retaining plate 82 align with the fifth row of battery cells1755. Further, the sixth row of apertures 1836 of the third retainingplate 80, and the sixth row of apertures 1866 of the fourth retainingplate 82 align with the sixth row of battery cells 1756. Further, theseventh row of apertures 1837 of the third retaining plate 80, and theseventh row of apertures 1867 of the fourth retaining plate 82 alignwith the seventh row of battery cells 1757.

First Outer Plate

Referring to FIGS. 8, 14, 29 and 58-61 , a first outer plate 90 iscoupled to the first retention housing 54 and the first and secondexterior plates 141, 142 of the battery cell retention frame 50. Thefirst outer plate 90 includes a plate portion 1900 and retaining clipmembers 1902, 1904. Referring to FIG. 59 , the plate portion 1900 hastab members 1910 and 1912 extending outwardly from the plate portion1900. Further, the plate portion 1900 has apertures 1921, 1922, 1923,1924 extending therethrough. The retaining clip members 1902, 1904 arecoupled to the plate portion 1900 extend in a first direction from theplate portion 1900. In an exemplary embodiment, the first outer plate 90is constructed of plastic.

Referring to FIGS. 29 and 59 , the retaining clip member 1902 is coupledto the tab member 636 (shown in FIG. 29 ) of the first retention housing54. Further, the retaining clip member 1904 is coupled to the tab member634 (shown in FIG. 29 ) of the first retention housing 54.

Referring to FIGS. 59 and 68 , the tab member 1912 is coupled to aretaining clip member 2202 (shown in FIG. 68 ) of the cover plate 126.Further, the tab member 1910 is coupled to a retaining clip member 2201(shown in FIG. 68 ) of the cover plate 126.

Referring to FIGS. 8, 13, 14 and 59 , the bolt 91 (shown in FIG. 8 )extends through the aperture 1921 in the first outer plate 90, and intothe aperture 311 (shown in FIG. 14 ) of the first exterior plate 141 ofthe battery cell retention frame 50, to couple the first outer plate 90to the battery cell retention frame 50.

Further bolt 92 (shown in FIG. 8 ) extends through the aperture 1922 inthe first outer plate 90, and into the aperture 312 (shown in FIG. 14 )of the first exterior plate 141 of the battery cell retention frame 50,to couple the first outer plate 90 to the battery cell retention frame50.

Further bolt 93 (shown in FIG. 8 ) extends through the aperture 1923 inthe first outer plate 90, and into the aperture 371 (shown in FIG. 14 )of the second exterior plate 142 of the battery cell retention frame 50,to couple the first outer plate 90 to the battery cell retention frame50.

Further bolt 94 (shown in FIG. 8 ) extends through the aperture 1924 inthe first outer plate 90, and into the aperture 372 (shown in FIG. 14 )of the second exterior plate 142 of the battery cell retention frame 50,to couple the first outer plate 90 to the battery cell retention frame50.

Second Outer Plate

Referring to FIGS. 8, 13, 47 and 62-64 , a second outer plate 100 iscoupled to the second retention housing 74 and the first and secondexterior plates 141, 142 of the battery cell retention frame 50. Thesecond outer plate 100 includes a plate portion 2000 and retaining clipmembers 2002, 2004. The plate portion 2000 has tab members 2010 and 2012extending outwardly from the plate portion 2000. Further, the plateportion 2000 has apertures 2021, 2022, 2023, 2024 extendingtherethrough. The retaining clip members 2002, 2004 are coupled to theplate portion 2000 and extend in a first direction from the plateportion 2000. In an exemplary embodiment, the second outer plate 100 isconstructed of plastic.

Referring to FIGS. 47 and 63 , the retaining clip member 2002 is coupledto the tab member 1636 (shown in FIG. 47 ) of the second retentionhousing 74. Further, the retaining clip member 2004 is coupled to thetab member 1634 (shown in FIG. 47 ) of the second retention housing 74.

Referring to FIGS. 63 and 67 , the tab member 2012 is coupled to aretaining clip member 2204 (shown in FIG. 67 ) of the cover plate 126.Further, the tab member 2010 is coupled to a retaining clip member 2203(shown in FIG. 67 ) of the cover plate 126.

Referring to FIGS. 8, 13 and 63 , the bolt 101 (shown in FIG. 8 )extends through the aperture 2023 of the second outer plate 100, andinto the aperture 301 (shown in FIG. 13 ) of the first exterior plate141 of the battery cell retention frame 50, to couple the second outerplate 100 to the battery cell retention frame 50.

Further bolt 102 (shown in FIG. 8 ) extends through the aperture 2024 inthe second outer plate 100, and into the aperture 302 (shown in FIG. 11) of the first exterior plate 141 of the battery cell retention frame50, to couple the second outer plate 100 to the battery cell retentionframe 50.

Further bolt 103 (shown in FIG. 8 ) extends through the aperture 2021 inthe second outer plate 100, and into the aperture 361 (shown in FIG. 13) of the second exterior plate 142 of the battery cell retention frame50, to couple the second outer plate 100 to the battery cell retentionframe 50.

Further bolt 104 (shown in FIG. 8 ) extends through the aperture 2022 insecond outer plate 100, and into the aperture 362 (shown in FIG. 13 ) ofthe second exterior plate 142 of the battery cell retention frame 50, tocouple the second outer plate 100 to the battery cell retention frame50.

Circuit Board

Referring to FIGS. 8 and 66 , the circuit board 120 includes a batterymanagement controller 2100 (shown in FIG. 8 ) that is electricallycoupled to the first and second plurality of cylindrical battery cells56, 76 to monitor the operation of the battery cells 56, 76. The circuitboard 120 is coupled to an end of the first retention housing 54 and thesecond retention housing 74.

Electrical Bus Bar

Referring to FIG. 8 , the electrical bus bar 122 is provided toelectrically couple together the first plurality of cylindrical batterycells 56 and the second plurality of battery cells 76. In particular,the electrical bus bar 122 is electrically coupled to the electrical busbar 458 (which is electrically coupled to the battery cells 56) and tothe electrical bus bar 1456 (which is electrically coupled to thebattery cells 76).

Cover Plate

Referring to FIGS. 8 and 66-68 , the cover plate 126 is attached to thefirst and second outer plates 90, 100 to cover the circuit board 120.The cover plate 126 includes a plate portion 2200, and retaining clipmembers 2201, 2202, 2203, 2204, 2205, 2206 extending in a firstdirection from the plate portion 2200. The retaining clip members 2201,2202 engage the tab members 1912, 1910 (shown in FIG. 59 ),respectively, of the first outer plate 90. The retaining clip members2203, 2204 engage the tab members 2010, 2012 (shown in FIG. 63 ),respectively, of the second outer plate 100. The retaining clip members2205, 2206 engage corresponding tab members to couple the cover plate126 to the first and second retention housings 54, 74. In an exemplaryembodiment, the cover plate 126 is constructed of plastic.

Referring to FIGS. 69-73 , a portion of the assembly steps forassembling the battery module 32 are illustrated. As shown in FIG. 69 ,the first and second retention housings 54, 74 holding the first andsecond plurality of cylindrical battery cells 56, 76, respectively,therein are moved towards the battery cell retention frame 50. Referringto FIGS. 70 and 71 , the first and second retention housings 54, 74 arecoupled together and further coupled to the battery cell retention frame50. Referring to FIG. 72 , the first and second outer plates 90, 100 aremoved toward the first and second retention housings 54, 74,respectively. Referring to FIG. 73 , the first and second outer plates90, 100 are coupled to the first and second retention housings 54, 74,respectively.

Referring to FIGS. 1, 10 and 20 , the operation of the battery system 20will now be explained in greater detail.

As a general overview, the fluid supply device 40 pumps a fluid throughthe inlet port 640 of the first retention housing 54 and into thecentral cooling plate member 140 of the battery cell retention frame 50.The central cooling plate member 140 conducts heat energy from the firstand second plurality of cylindrical battery cells 56, 76 into the fluid.The fluid flows from the central cooling plate member 140 and out of theoutlet port 1640 of the second retention housing 74 to cool the firstand second plurality of cylindrical battery cells 56, 76.

A more detailed explanation of the operation of the battery system 20will now be provided. The fluid supply device 40 pumps a fluid throughthe conduit 42 to the inlet port 640 of the battery cell retention frame50. The fluid flows from the inlet port 640 and into an inlet aperture208 (shown in FIG. 20 ) of the first manifold portion 161 and then intothe longitudinal aperture 210 of the first manifold portion 161. Fromthe longitudinal aperture 210, the fluid flows through a flow aperture214 of the first manifold portion 161 and into the internal coolingchannel 184. The fluid flows through the internal cooling channel 184and through a flow aperture 244 of the second manifold portion 162 andinto the longitudinal aperture 240 of the second manifold portion 162.From the longitudinal aperture 240, the fluid flows through the outletaperture 238 of the second manifold portion 162 and the outlet port 1640and then through the conduit 44 to the fluid supply device 40. Referringto FIG. 10 , while the fluid is flowing through the battery cellretention frame 50, heat energy is transferred from the first pluralityof cylindrical battery cells 56 and the second plurality of cylindricalbattery cells 76 to the battery cell retention frame 50 and into thefluid flowing through the battery cell retention frame 50 to cool thebattery cells 56, 76.

Referring to FIGS. 3, 19 and 74 , the battery module 32 can cool thefirst and second plurality of cylindrical battery cells 56, 76 withoututilizing the fluid supply system 30. In particular, the central coolingplate member 140 of the battery cell retention frame 50 conducts heatenergy from the first and second plurality of cylindrical battery cells56, 76 through the frame 54 to the first and second exterior plates 141,142 of the battery cell retention frame 50 to cool the battery cells 56,76. The first and second exterior plates 141, 142 conduct the heatenergy to ambient air proximate to the first and second exterior plates141, 142.

The battery system 20 having the battery module 32 provides asubstantial advantage over other systems. In particular, an advantage ofthe battery module 32 is that the battery module 32 utilizes the firstand second retention housings 54, 74 to hold the battery cell retentionframe 50 therein that can be either air cooled or fluid cooled. Inparticular, the first and second retention housings 54, 74 have an inletport 640 and an outlet port 1640, respectively, for routing fluidthrough the battery cell retention frame 50 for cooling cylindricalbattery cells thereon. Alternately, the battery cell retention frame 50can be air cooled for cooling the cylindrical battery cells. Also, thefirst and second retention housings 54, 74 provide improved structuralintegrity to the battery module 32.

While the claimed invention has been described in detail in connectionwith only a limited number of embodiments, it should be readilyunderstood that the invention is not limited to such disclosedembodiments. Rather, the claimed invention can be modified toincorporate any number of variations, alterations, substitutions orequivalent arrangements not heretofore described, but which arecommensurate with the spirit and scope of the invention. Additionally,while various embodiments of the claimed invention have been described,it is to be understood that aspects of the invention may include onlysome of the described embodiments. Accordingly, the claimed invention isnot to be seen as limited by the foregoing description.

What is claimed is:
 1. A battery module, comprising: a battery cell retention frame having a central cooling plate member, and first and second exterior plates; the central cooling plate member having first and second manifold portions and first and second intermediate walls disposed between and coupled to the first and second manifold portions; the first and second intermediate walls defining an internal cooling channel therebetween that fluidly communicates with the first and second manifold portions; the first and second exterior plates being coupled to the first and second manifold portions, respectively, and extending perpendicular to the central cooling plate member; a first retention housing being disposed within a region defined by the first intermediate wall and the first and second exterior plates, the first retention housing having an end wall and first, second, third, and fourth side walls defining a first interior region; the first, second, third, and fourth side walls of the first retention housing being coupled to the end wall thereof and defining a first open end; the first retention housing holding a first plurality of cylindrical battery cells therein that thermally communicate with the first intermediate wall; the first side wall of the first retention housing having an inlet port that fluidly communicates with the first manifold portion; and a second retention housing being disposed within a region defined by the second intermediate wall and the first and second exterior plates, the second retention housing having an end wall and first, second, third, and fourth side walls defining a second interior region; the first, second, third, and fourth side walls of the second retention housing being coupled to the end wall thereof and defining a second open end, the second retention housing holding a second plurality of cylindrical battery cells therein that thermally communicate with the second intermediate wall, the first side wall of the second retention housing having an outlet port that fluidly communicates with the second manifold portion.
 2. The battery module of claim 1, wherein: the first retention housing having a first retaining clip member on the first side wall thereof; and the second retention housing having a first tab member on the first side wall thereof such that the first retaining clip member engages the first tab member to couple the first retention housing to the second retention housing.
 3. The battery module of claim 2, wherein: the first retention housing having a second retaining clip member on the second side wall thereof; and the second retention housing having a second tab member on the second side wall thereof such that the second retaining clip member engages the second tab member to couple the first retention housing to the second retention housing.
 4. The battery module of claim 1, further comprising: a first electrical bus bar coupled to the third side wall of the first retention housing, the first electrical bus bar being further electrically coupled to the first plurality of cylindrical battery cells; and a second electrical bus bar coupled to the fourth side wall of the first retention housing, the second electrical bus bar being further electrically coupled to the second plurality of cylindrical battery cells.
 5. The battery module of claim 1, wherein: the end wall of the first retention housing having a plurality of apertures extending therethrough.
 6. The battery module of claim 5, wherein: each aperture of the plurality of apertures in the end wall of the first retention housing being sized and shaped such that each cylindrical battery cell has a positive terminal and a negative terminal that is accessible through a respective aperture of the plurality of apertures.
 7. The battery module of claim 5, wherein: the end wall of the first retention housing having a plurality of engagement tab groups that extend toward the first open end, each engagement tab group of the plurality of engagement tab groups contacts an outer surface of a respective cylindrical battery cell of the plurality of cylindrical battery cells such that the respective cylindrical battery cell is aligned with a respective aperture of the plurality of apertures in the end wall of the first retention housing.
 8. The battery module of claim 1, further comprising: a first retaining wall having a plurality of holes extending therethrough; the first retaining wall being coupled to the first retention housing within the first interior region to hold the first plurality of cylindrical battery cells between the first retaining wall and the end wall of the first retention housing; and a bottom surface of the plurality of cylindrical battery cells extending through plurality of holes and contacting a first thermally conductive layer on the first intermediate wall.
 9. The battery module of claim 1, further comprising: a first outer plate coupled to the first retention housing and the first and second exterior plates of the battery cell retention frame.
 10. The battery module of claim 9, further comprising: a second outer plate coupled to the second retention housing and the first and second exterior plates of the battery cell retention frame.
 11. The battery module of claim 9, wherein: the first outer plate having a first retaining clip member; and the first retention housing having a first tab member on the first side wall thereof such that the first retaining clip member of the first outer plate engages the first tab member to couple the first outer plate to the first retention housing.
 12. The battery module of claim 11, further comprising: first and second bolts; the first outer plate having first and second apertures extending therein; the first and second exterior plates of the battery cell retention frame having first and second apertures extending therein; the first bolt extending through the first aperture of the first outer plate and the first aperture of the first exterior plate to couple to the first outer plate to the battery cell retention frame; and the second bolt extending through the second aperture of the second outer plate and the second aperture of the first exterior plate to couple to the first outer plate to the battery cell retention frame.
 13. The battery module of claim 1, wherein: the battery cell retention frame further includes first and second thermally conductive layers being coupled to the first and second intermediate walls, respectively.
 14. The battery module of claim 1, wherein: a structure of the first retention housing is identical to a structure of the second retention housing.
 15. The battery module of claim 1, wherein: a fluid flows through the inlet port of the first retention housing and into the central cooling plate member, the central cooling plate member conducts heat energy from the first and second plurality of cylindrical battery cells into the fluid, the fluid flows from the central cooling plate member and out of the outlet port of the second retention housing to cool the first and second plurality of cylindrical battery cells.
 16. The battery module of claim 1, wherein: the central cooling plate member conducts heat energy from the first and second plurality of cylindrical battery cells through the central cooling plate member to the first and second exterior plates to cool the first and second plurality of cylindrical battery cells, the first and second exterior plates conduct the heat energy to ambient air proximate to the first and second exterior plates.
 17. A battery system, comprising: a battery module having a battery cell retention frame, a first retention housing, and a second retention housing; the battery cell retention frame having a central cooling plate member, and first and second exterior plates; the central cooling plate member having first and second manifold portions and first and second intermediate walls disposed between and coupled to the first and second manifold portions; the first and second intermediate walls defining an internal cooling channel therebetween that fluidly communicates with the first and second manifold portions; the first and second exterior plates being coupled to the first and second manifold portions, respectively, and extending perpendicular to the central cooling plate member; the first retention housing being disposed within a region defined by the first intermediate wall and the first and second exterior plates, the first retention housing having an end wall and first, second, third, and fourth side walls defining a first interior region; the first, second, third, and fourth side walls of the first retention housing being coupled to the end wall thereof and defining a first open end; the first retention housing holding a first plurality of cylindrical battery cells therein that thermally communicate with the first intermediate wall; the first side wall of the first retention housing having an inlet port that fluidly communicates with the first manifold portion; and the second retention housing being disposed within a region defined by the second intermediate wall and the first and second exterior plates, the second retention housing having an end wall and first, second, third, and fourth side walls defining a second interior region; the first, second, third, and fourth side walls of the second retention housing being coupled to the end wall thereof and defining a second open end, the second retention housing holding a second plurality of cylindrical battery cells therein that thermally communicate with the second intermediate wall, the first side wall of the second retention housing having an outlet port that fluidly communicates with the second manifold portion; a fluid supply system being fluidly coupled to the inlet port and the outlet port, the fluid supply system supplying a fluid to the inlet port such the fluid flows through the first manifold portion of the battery cell retention frame and the internal cooling channel of the battery cell retention frame, and the second manifold portion of the battery cell retention frame and out of the outlet port to extract heat energy from the first and second plurality of battery cells.
 18. The battery system of claim 17, wherein: the fluid supply system includes a fluid supply device and first and second conduits, the first conduit coupled to and between the fluid supply device and the inlet port, the second conduit coupled to and between the fluid supply device and the outlet port. 